automatic transaxle DAEWOO NUBIRA 2004 Service Repair Manual

5A1 – 216IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
11. Take out the snap ring.
12. Remove disc set E.
13. Press down cup spring(clutch E) with cup spring
press fixture.
14. Remove the split stop ring.
15. Remove the oil dam and cup spring.
16. Pull the o–ring off the oil dam.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 217
DAEWOO V–121 BL4
17. Press down cup spring(clutch B)with cup spring
press fixture.
18. Remove the split stop ring.
19. Remove the cup spring.
20. Installation should follow the removal procedure in
the reverse order.
Adjustment Notice
Before assembling clutch B/E, setting discs(clutch B/E)
have to measured by below measurement procedure.
CLUTCH B/E MEASUREMENT
PROCEDURE
Tools Required
DW260–090 Clutch B/E(snap ring play, installation space)
Measuring Fixture
Determine Snap Ring Play
1. Put the dial gauge sensor on the clutch B adjusting
ring.
2. Feed compressed air to clutch B via control valves.
3. Set dial gauge to zero.
4. Pressurize clutch E via the control valve and read
measurement value.
5. Repeat measurement twice with disc set turned by
120°.
6. Average measurement values M1, M2, M3.(mea-
surement value is S)
S CALCULATION
S = (M1+M2+M3)/3
S EXAMPLE
– M1 = 0.27mm, M2 = 0.23mm, M3 = 0.25mm
– S = 0.25mm

5A1 – 218IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Tools Required
DW260–090 Clutch B/E (snap ring play, installation
space) Measuring Fixture
Measuring Installation Space, Clutch B
(EB)
1. Put the dial gauge’s sensor on the clutch B adjust-
ing ring.
2. Feed compressed air to clutch E via control valves.
3. Set dial gauge to zero.
4. Lift measurement ring B by hand until it touches the
cup and read the measurement value.
5. Repeat measurement twice with the set turned by
120°.
6. Average measurement values M4, M5, M6. (mea-
surement value is MB)
S The minimum installation space EB is equal to
the height of the ring RB (specification value ;
11.99mm) plus measurement value MB
S CALCULATION
MB = (M4+M5+M6)/3
EB = RB + MB
S EXAMPLE
M4 = 2.36mm
M5 = 2.40mm
M6 = 2.38mm
So,MB = (2.36+2.40+2.38)/3 = 2.38mm
EB = 11.99+2.38 =14.37mm
Tools Required
DW260–090 Clutch B/E(snap ring play, installation space)
Measuring Fixture
Measuring Installation Space, Clutch E(EE)
1. Put the dial gauge’s sensor on the clutch E adjust-
ing ring.
2. Set dial gauge to zero.
3. Feed compressed air to clutch E via control valves.
4. Read off the measured value.
5. Repeat measurement twice with the set turned by
120°.
6. Average measurement values M7, M8, M9. (mea-
surement value is ME)
S The minimum installation space BE is equals
ring height RE (specification value : 20.98mm)
plus ME – minus snap ring play S.
S CALCULATION
ME = (M7+M8+M9)/3
EE = RE + ME–S
S EXAMPLE
M7 = 2.6mm
M8 = 2.55mm
M9 = 2.54mm
So,ME = (2.6+2.55+2.54)/3 = 2.56mm
EE = 20.98+2.56–0.25 = 23.29mm

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 219
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Tools Required
DW260–100 Brake B/E Disc Thickness Measuring Fixture
Determining Adjusting Disc B(PB)
1. Using disc thickness gauge, determine thickness
ME for the disc set for clutch B(without adjusting
disc, which located in second highest plate).
2. Calculate the test dimension PB(PB = EB – MB)
EB = installation space
MB = disc set thickness
S EXAMPLE
EB = 14.37mm
MB = 11.3mm
PB = 3.07mm
3. Find the disc set’s thickness. Refer to the below
table.
PB
Disc set’s Thickness
2.83~3.39mm1.8mm
3.40~3.68mm2.1mm
3.69~4.08mm2.5mm
4.09~4.54mm3.0mm
PB is 3.08mm so, the disc set’s thickness is
1.8mm.
4. Replace clutch B’s setting disc. (1.8mm)
Tools Required
DW 260–100 Brake B/E Disc Thickness Measuring Fix-
ture
Determining Adjusting Disc E(PE)
1. Using disc thickness gauge, determine thickness
MB for the disc set for clutch E(without adjusting
disc, which located in the lowest plate).
2. Calculate the test dimension PE(PE = EE – ME)
EE = installation space
MB = disc set thickness
S EXAMPLE
EE = 23.29mm
ME = 16.70mm
PE = 6.59mm
3. Find the disc set’s thickness. Refer to the below
table.
PE
Disc set’s Thickness
5.41~6.00mm3.9mm
6.01~6.48mm4.4mm
6.49~6.98mm5.0mm
PB is 3.08mm so, the disc set’s thickness is
5.0mm.
4. Replace clutch B’s setting disc. (5.0mm)

5A1 – 220IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
PLANETARY GEAR SET
Disassembly and Assembly Procedure
1. Remove the clutch B/E. Refer to ”Clutch B/E” in
this section.
2. Remove the rear sun gear.
3. Remove the planetary gear set.
4. Remove snap ring from front ring gear.
5. Take out rear planetary gear set.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 221
DAEWOO V–121 BL4
6. Remove the axial needle bearing.
7. Take out front gear set with rear ring gear, front sun
gear and oil trays.
8. Take oil trays and front sun gear off the planetary
gear set.
9. Installation should follow the removal procedure in
the reverse order.
BRAKE C/D
Tools Required
DW260–160 Brake C/D Snap Ring Remover/Installer
Disassembly and Assembly Procedure
1. Take snap ring out of transaxle housing.

5A1 – 222IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
2. Release cylinder with piston C by applying com-
pressed air to the feed bore .
3. Remove cylinder with piston C.
4. Take disc carrier C/D and spring disc out of trans-
axle housing.
5. Release cylinder with piston D by applying com-
pressed air to the feed bore.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 223
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6. Remove cylinder with piston C.
7. Separate between piston C and cylinder C.
8. Take snap ring out of brake C.
9. Remove the disc set C.
Installation Notice
S Transaxle has two lined clutch discs and one
steel clutch disc. The lined discs must be
installed in such a way that the lining faces the
steel disc.
S Insert the fitting keys into the appropriate
grooves.

5A1 – 224IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
10. Turn the disc carrier C/D by 180°.
11. Using assembly bracket Press down cup spring and
take out the snap ring.
12. Remove the disc set D.
13. Installation should follow the removal procedure in
the reverse order.
DIFFERENTIAL
Disassembly and Assembly Procedure
1. Remove the torque converter housing. Refer to
”Torque Converter” in this section.
2. Lift out the differential.
3. Installation should follow the removal procedure in
the reverse order.
Removal Notice
S Don’t disassemble the differential to avoid incorrect
operation.
SIDE SHAFT
Disassembly and Assembly Procedure
1. Remove the differential. Refer to ”Differential” in
this section.
2. Tilt and remove the side shaft.
3. Installation should follow the removal procedure in
the reverse order.
Removal Notice
S Don’t disassemble the differential to avoid incorrect
operation.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 225
DAEWOO V–121 BL4
BRAKE F, SLOTTED NUT
Tools Required
DW260–060 Brake F Split Stop Ring Remover
Disassembly and Assembly Procedure
1. Remove the side shaft. Refer to ”Side Shaft” in this
section.
2. Take OFF the disc set and the brake F inner disc
carrier.
3. Mount fixture and remove the brake F split stop
ring.
4. Remove the fixture and take off the cup spring.